Etex Tisselt: 28% reduction in water consumption by 2030
Etex Building Performance in Tisselt (Etex NV) mainly produces calcium silicate boards, as well as fire-resistant plasterboards and xonotlite powder. The production of calcium silicate boards is inherently water-intensive, making this the most water-intensive site within the Etex Group.
As part of Etex’s sustainability objectives, the Tisselt site was set a clear target: to reduce water consumption by 30% by 2030.
Sweco supported Etex with a water management plan that maps out current water consumption and defines concrete measures to optimise and reduce water flows and, where possible, reuse them within production.
Expertise:
Industrial solutions, Water
Client
Etex
Location
Tisselt, Belgium
Sweco scope
Water audit and water management plan: inventory of water consumption, analysis of water flows sent to water treatment and identification of reuse and reduction measures.
Inventory of current water consumption
The basis of the water management plan is a detailed inventory of the water flows on site. The site’s water supply is dominated by canal water (±97%), alongside mains water (±3%) for sanitary use and critical processes.
Sweco investigated the extent to which water flows currently discharged to the water treatment plant can be reused in alternative applications within the production process.
The result is a set of measures that together deliver a potential reduction of 28%, close to the 30% target for 2030.
Identifying the measures with the greatest reuse potential
Reuse of rinsing water from two vacuum belts
On the vacuum belts, the product is first rinsed, after which the rinsing water is extracted.
Sweco proposes reusing this rinsing water.
The rinsing water is:
passed through a pre-settling tank,
transferred to a buffer tank,
and then reused on the same two vacuum belts.
This reduces both fresh water use and the load sent to water treatment.
More efficient production of demineralised water via UF/RO
Demineralised water, or demi water, is an important input in the production process.
Sweco proposes optimising the production of demineralised water with a UF/RO system, which combines ultrafiltration with reverse osmosis.
Additional benefit
The production of demineralised water currently uses softeners, among other equipment. These need to be regenerated regularly with salt, which means the salt component chloride ends up in the wastewater – an undesirable outcome.
With the UF/RO system, the softener stage becomes unnecessary:
Sweco identified additional opportunities for reduction and reuse.
Reuse of a specific residual process stream
Our consultants examined the different water flows sent to water treatment. They identified a residual stream with water quality similar to a stream that is already being reused today. Making additional use of this residual stream can reduce the use of canal water.
Reuse of condensate from two ovens
Reprogramming a water jet
By converting a continuous water flow into intermittent operation, consumption can be reduced further.
Monitoring as the next step
Our consultants recommend installing flow meters at strategic locations. This will enable Etex to monitor water consumption and the impact of measures even more accurately in the near future.
Better data quality
= better control, reporting and future optimisation.
Impact
With the water management plan for Etex Tisselt, Sweco provides a well-substantiated roadmap to structurally reduce water consumption and increase reuse.
The proposed measures enable the site to achieve a potential 28% reduction in water consumption and form a solid basis for achieving the 30% target by 2030 through additional monitoring and further development of opportunities.
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